Control valve

ABSTRACT

A control valve body has a flow passage including an inlet, an outlet, a first portion, and a second portion, the first portion having a first axis centered through the inlet, a first bend, and a second axis, the second portion having a third axis centered through the outlet, a second bend, and a fourth axis, the fourth axis perpendicular to the second axis. The first portion is to an upstream side of a junction of the first portion and the second portion, and the second portion is to a downstream side of the junction. The second axis is centered through the junction. An opening to the second portion has a fifth axis aligned with the second axis.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of co-pending U.S. patentapplication Ser. No. 17/217,536, filed Mar. 30, 2021, titled “CONTROLVALVE”. U.S. patent application Ser. No. 17/217,536 is incorporatedherein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The invention pertains to the field of valves. More particularly, theinvention pertains to control valves with improved flow and flow rate.

A control valve is a valve used to control fluid flow by varying thesize of a flow passage, enabling the direct control of flow rate and theconsequential control of process quantities such as pressure,temperature, and fluid level. FIG. 1 illustrates a cross section of aconventional control valve 10. FIG. 2 shows an external perspective viewof the conventional control valve 10. The control valve 10 includes abody 12, a flow passage 14 through the body 12, and a valve plug 16 toseal with a seat ring 18 and close the flow passage 14. The plug 16 isattached to a stem 20, which can move linearly along an axis of the stemto move the plug 16 between a closed position, where the plug 16 fillsan opening through the seat ring 18, and an open position, where theplug 16 is moved out of the opening through the seat ring 18.

The body 12 has a first leg 22 with an inlet opening 23 and a second leg24 with an outlet opening 25. The first leg 22 and the second leg 24intersect at the seat ring 18. A plane of the seat ring 18 is parallelto an axis of either the inlet opening 23 of the first leg 22 or theoutlet opening 25 of the second leg 24, and the stem 20 extends andmoves perpendicularly to the plane of the seat ring 18 and the axis ofeither the inlet opening 23 of the first leg 22 or the outlet opening 25of the second leg 24. In other words, an axis of the seat ring 18 isperpendicular to the inlet opening 23 and/or the outlet opening 25. Aseat retainer 26 includes many support members 27 that extend from theseat ring 18 through the flow passage 14 at the second leg 24, and braceagainst another secure part of the control valve 10 to hold the seatring 18 in position. The first leg 22 and the second leg 24 are round inshape near or around the seat ring 18.

During operation of the control valve 10, when the control valve 10 isopen, fluid flows from the inlet opening 23, changing direction twice toget through the first leg 22 to the seat ring 18, where the fluid isredirected about 90 degrees through the seat ring 18. After travelingthrough the seat ring 18, the fluid is again redirected twice beforepassing through the outlet opening 25—first more than 90 degrees andthen again reduce the net redirection to 90 degrees at the outletopening 25. The sharp angles and total sum of angles at which the fluidis redirected causes turbulence and slows the flow rate. Further, theplurality of support members 27 of the seat retainer 26 obstruct flow,further exacerbating the turbulence and flow interruption.

SUMMARY OF THE INVENTION

A control valve is provided to reduce turbulence and to increase flowrate relative to conventional control valves. In an embodiment, acontrol valve includes a body, a valve seat, a stem, and a seal. Thebody has a flow passage therethrough, the flow passage having an inlet,an outlet, a first portion, and a second portion, the first portionhaving a first axis centered through the inlet, the second portionhaving a second axis centered through the outlet, the first axisparallel with the second axis. The valve seat is positioned at ajunction between the first portion and the second portion, the firstportion being to an upstream side of the valve seat and the secondportion being to a downstream side of the valve seat, the valve seathaving an opening therethrough. The stem has a third axis oriented tointersect with the opening of the valve seat. The seal is attached tothe stem, the stem configured to move axially to move the seal between aclosed position, where the seal fills the opening through the valveseat, and an open position, where the seal is distal from the valveseat.

In an embodiment, a control valve body includes a flow passage and anopening. The flow passage has an inlet, an outlet, a first portion, asecond portion, and a junction of the first portion with the secondportion, the first portion having a first axis centered through theinlet, a first bend, and a second axis, the second portion having athird axis centered through the outlet, a second bend, and a fourthaxis, the fourth axis perpendicular to the second axis, the firstportion being to an upstream side of the junction and the second portionbeing to a downstream side of the junction, the second axis centeredthrough the junction. The opening is to the second portion. The openinghas a fifth axis aligned with the second axis.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross section of a conventional control valve.

FIG. 2 shows a perspective view of a portion of the conventional controlvalve of FIG. 1 .

FIG. 3 illustrates a perspective view of a control valve, according toan embodiment of the invention.

FIG. 4 illustrates a cross section of the control valve of FIG. 3 , withthe control valve in closed position.

FIG. 5 illustrates a cross section of the control valve of FIG. 3 , withthe control valve in an open position.

FIG. 5A illustrates a perspective view of a sleeve and a bushing,according to an embodiment of the invention.

FIG. 6 illustrates a top view of a valve body of the control valve ofFIG. 3 .

FIG. 7 illustrates a cross sectional view of the valve body of FIG. 6 .

DETAILED DESCRIPTION OF THE INVENTION

In the following description, reference is made to the accompanyingdrawings that form a part thereof, and in which is shown by way ofillustration specific example embodiments in which the present teachingsmay be practiced. These embodiments are described in sufficient detailto enable those skilled in the art to practice the present teachings andit is to be understood that other embodiments may be utilized and thatchanges may be made without departing from the scope of the presentteachings. The following description is, therefore, merely exemplary.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a”, “an”, and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”,“connected to” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto”, “directly connected to” or “directly coupled to” another element orlayer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”,“lower”, “above”, “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the figures. For example, if the device in the figures is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

The terms “approximately” and “about”, when qualifying a quantity, shallmean the quantity with a tolerance plus or minus 10 percent of thequantity, unless otherwise specified.

A control valve is provided to reduce turbulence and to increase flowrate relative to conventional control valves. FIG. 3 illustrates aperspective view of a control valve 100, according to an embodiment ofthe invention. FIG. 4 and FIG. 5 illustrate a cross-section of thecontrol valve 100 in a closed position and in an open position,respectively. According to FIGS. 3-5 , the control valve 100 includes abody 102 having a flow passage 104 through which fluid flows. The flowpassage 104 has an inlet 106, an outlet 108, a first portion 110, and asecond portion 112. Fluid, such as but not limited to water, can enterthe flow passage 104 at the inlet 106, flow through the first portion110, to the second portion 112, and out the outlet 108.

A valve seal 116 is positioned at a junction 118 of the first portion110 and the second portion 112 to control fluid flowing through the flowpassage 104. The first portion 110 is to an upstream side of thejunction 118 and the second portion 112 is to a downstream side of thejunction 118. In the illustrated embodiment, the valve seal 116 is adisk 114 with a seal ring 115 held between the disk 114 and a retainerring 117 fastened to the disk 114. The seal ring 115 extends around aperiphery or circumference of the disk 114, though the valve seal 116could be a plug or have other shapes. The valve seal 116 can be movedinto and out of the junction 118, to close the flow passage 104 at thejunction 118 (see FIG. 4 ), or to open the flow passage 104 at thejunction 118 (see FIG. 5 ).

In the closed position of FIG. 4 , the valve seal 116 fills an openingof a valve seat 120, with the seal ring 115 contacting and sealingagainst the valve seat 120, which, in turn, contacts and seals againstthe body 102 of the control valve 100 at the junction 118, such that inthe closed position, the body 102, the valve seat 120, and the valveseal 116 form a fluid tight barrier to prevent fluid from flowingthrough the junction 118. To form the fluid-tight connection with thebody 102, the valve seat 120 is shaped congruently with the innersurface of the body 102 at the junction 118. In the illustratedembodiment, this shape of the valve seat 120 is that of a ring. Bolts,screws, or other fasteners (not shown) can secure the valve seat 120 tothe body 102 of the control valve 100. Notably, the valve seat 120 isattached securely to the body 102 at the junction 118 without supportmembers or other elements projecting from the ring through the flowpassage 104 to another portion or component of the control valve 100.This absence of flow-obstructing elements facilitates an increased flowrate and a decreased turbulence relative to conventional control valves.

In the open position, as illustrated in FIG. 5 , the valve seal 116 ismoved to a location distal from the valve seat 120, which allows fluidto flow through the junction 118. The valve seal 116 can be moved to anylocation between the closed position and the open position to controlthe flow rate.

The valve seal 116 is attached to a stem 122 and is moved between theclosed position and the open position along with, and guided by, thestem 122. The axis 124 of the stem 122 is oriented to intersect with thejunction 118 and the opening through the valve seat 120. The stem 122,and hence the valve seal 116, are restricted to move along an axis 124of the stem 122 by mechanisms at a first end 126 and a second end 128 ofthe stem 122.

Referring additionally to FIG. 5A, which shows a perspective view of asleeve 130 and bushing 132, at the first end 126, the stem 122 isinserted into a sleeve 130 secured to the body 102 in the first portion110 of the flow passage 104. The sleeve 130 has an elongated body with ahollow portion 131 opening at a first end 133 to receive the stem 122. Asleeve bushing 132 in the hollow portion 131 of the sleeve 130facilitates sliding movement of the stem 122 in the sleeve 130. At anopposite end 135 of the sleeve 130, an outer diameter of the sleeve 130tapers across a distance toward the first end 133. An opening 137through the body 102 of the control valve 102 to the first portion 110is aligned with the axis 124 of the stem 122. The first end 133 of thesleeve 130 is sized to fit through the opening 137 in the body 102 ofthe control valve 100, and the opposite end 135 with the taperingdiameter is configured to press fit into and seal the opening 137. Aposition of the first end 133 of the sleeve 130 is secured and held inposition by a rigidity of the sleeve material and the press-fit of theopposite end 135 in the opening 137. A relief hole 139 between the firstend 133 and the opposite end 135 can relieve and/or prevent positiveand/or negative pressure change in the hollow portion 131 as the sleeve130 slides therein.

At the second end 128, the sleeve 122 is inserted through a bearing 134and a receptacle 136 of a top cover 138 of a bonnet 140. The bearing 134facilitates sliding of the stem 122 at the second end 128 of the stem122. The stem 122 is biased toward the closed position by a spring 142positioned around the stem 122 between the top cover 138 and the valveseal 116.

The top cover 138 is attached to the bonnet 140, which is attached tothe body 102 of the control valve 100 to cover an opening 144 (see FIG.6 ) through the body 102 into the second portion 112 of the flow passage104. The top cover 138 has a plug 146 to plug an end of the receptacle136. The plug 146 can be removed to access the receptacle 136, the stem122, and the bearing 134. The top cover 138 cover can be removed fromthe bonnet 140 to access an interior space 148 between the bonnet 140and the second portion 112 of the flow passage 140, and to access thespring 142. A diaphragm 150 is compressed between the bonnet 140 and aflange 152 around the opening 144 (see FIG. 6 ) in order to seal fluidfrom entering the interior space 148 from the second portion 112 of theflow passage 104. The diaphragm 150 is secured and/or compressed betweenthe valve seal 116 and a plate 154, such that the diaphragm 150 can moveand/or stretch to move with the valve seal. An o-ring 156 seals betweenthe stem 122 and the valve seal 116, completing the seal of fluid fromflowing into the interior space 148 from the second portion 112 of theflow passage 104.

The shape of the valve body 102 and flow passage 104 further increasethe fluid flow rate capacity. The first portion 110 of the flow passage104 has a first axis 160 centered through the inlet 106. From the inlet106, nearing the junction 118, the first portion 110 has a bend 162 thatturns to intersect the second portion 112 at an angle of approximately90 degrees. The first portion 110 accordingly has a second axis 164centered through the junction 118, the valve seat 120, the valve seal116, the stem 122, and/or the opening 144 (see FIG. 6 ). The first axis160 is angled obliquely relative to the second axis 164. In someembodiments, a first oblique angle 166 between the first axis 160 andthe second axis 164 can range between 15 and 75 degrees. In someembodiments, the first oblique angle 166 can range between 45 and 65degrees. In some embodiments, the first oblique angle 166 can rangebetween 50 and 60 degrees. In some embodiments, the first oblique angle166 can be approximately 55 degrees. The first oblique angle 166 beingin these ranges, and particularly being approximately 55 degrees,combined with the shape of the flow channel, facilitates maximum flowrate capacity.

Because a plane 168 of the valve seat 120 and junction 118 isperpendicular to the second axis 164, the plane 168 can be angledobliquely relative to the first axis 160. This second oblique angle 169can be between 15 and 75 degrees from parallel with the first axis 160,between 25 and 45 degrees in some embodiments, between 30 and 40 degreesin some embodiments, or approximately 35 degrees in some embodiments.

The second portion 112 of the flow passage 104 has a third axis 170centered through the outlet 108. In the illustrated embodiment, thethird axis 170 is collinear with the first axis 160, though in someembodiments, the third axis 170 can be parallel but not collinear withthe first axis 160, and in some embodiments, the third axis 170 is notparallel with the first axis 160. From the outlet 108, nearing thejunction 118, the second portion 112 has a bend 172, after which thesecond portion 112 continues straight past the stem 122 and valve seal116 to an end 173 opposite the outlet 108. The second portion 112accordingly has a fourth axis 174, which is angled obliquely relative tothe third axis 170, and which is approximately perpendicular to thesecond axis 164. In some embodiments, this third oblique angle 176 canrange between 15 and 75 degrees. In some embodiments, the third obliqueangle 176 can range between 25 and 45 degrees. In some embodiments, thethird oblique angle 176 can range between 30 and 40 degrees. In someembodiments, the third oblique angle 176 can be approximately 35degrees.

As a result of this angular structure of the flow passage 104, the totaldirectional change of fluid as it flows from the inlet 106 through thefirst portion 110 to the second portion 112 and out the outlet 108 isdecreased with respect to conventional control valves, which decreasesturbulence and increases the flow rate capacity. How much thedirectional change of the flow passage 104 can be reduced is limited bythe structural components necessary to operate the valve seal 116 in theflow passage 104 and the desire to output fluid on the same axis asfluid enters the flow passage 104.

The structure and shape of the second portion 112 around the stem 122and the valve seal 116 further facilitates flow toward the outlet 108 tofurther decrease turbulence and improve the flow rate capacity of thecontrol valve 100. FIG. 6 illustrates a top view of the valve body 102,looking perpendicularly toward the first axis 160. FIG. 7 illustrates across sectional view of the valve body 102 looking perpendicularlytoward the fourth axis 174. Referring to FIG. 6 and FIG. 7 , in additionto FIGS. 3-5 , the second portion 112 is expanded around the second axis164 and the opening 144, as compared to the size of the outlet 108. Morespecifically, the second portion 112 opens from a cylindrical shape atthe outlet 108 to a three-dimensional, irregular disk shape around thesecond axis 164 and the opening 144. The three-dimensional disk shapehas a flat first side 180, a flat second side 182 opposite the firstside 180, and a height H. The end 173 of the second portion 112 has acurved wall 184 with a radius R1 and a center C. The second axis 164 andthe opening 144 are offset from the center C toward the end 173 of thesecond portion 112 opposite the outlet 108, such that a portion of theflange 152 around and adjacent the opening 144 is continuous with acurved wall 184 of the end 173, or such that the flange 152 covers thefirst side 180 between the opening 144 and the end 173. In other words,there is minimal space between the opening 144 and the end 173 of thesecond portion 112 only sufficient to make room for the flange 152. Insome embodiments, the flange 152 can be eliminated such that the curvedwall 184 at the end 173 are coplanar. Because of the resulting closeproximity of the second axis 164 and the opening 144 to the end 173 ofthe second portion 112, as fluid flows into the second portion 112 fromthe first portion 110, the fluid has relatively little space to flow“backwards”, and the fluid is instead expeditiously forced to movetoward the outlet 108.

Further, a wall 175 of the body 102 at the end 173 of the second portion112 between the first side 180 and the second side 182 is essentiallyflat and/or straight across the height H from the first side 180 to thesecond side 182, to further limit the flow “backwards” or “sideways”,and to instead force fluid to expeditiously flow toward the outlet 108.The only curvature of the wall 175 moving along the span of the height Hat the end 173 can be the roundedness of rounded corners 177 at a unionof the wall 175 and the first side 180 or at a union of the wall 175 andthe second side 182. “Essentially straight” or “essentially flat” isintended to mean that the wall is straight excluding any relativelysmall roundedness at the union of the wall 175 with the first side 180or the second side 182. The wall 175, extending laterally past andaround the axis 164 to the outlet 108, can be essentially flat and/orstraight in this manner across the height H.

Further, the offset of the opening 144 and the axis 164 toward the end173, along with the radius R1 being greater than a radius R2 of theopening 144 results in an expansion of a volume of the second portion112 between the body 102 and the second axis 164 laterally around thesecond axis 164, and from the end 173, toward the outlet 108, therebydrawing the fluid forward of the axis 164 before the volume decreases tothe outlet 108. In the illustrated embodiment, the end 173 has arelatively large radius R1 of 190.5 mm (7.5 inches), which transitionsto a radius R3 of 76.2 mm (3.0 inches), and then a first straight edge186 parallel with the fourth axis 174. A second straight edge 188 bends15 degrees inward from the first edge 186 to begin tapering to thediameter D of the outlet 108. The quick expansion from the end 173 to apoint between the second axis 164 and the outlet 108 further draws fluidtoward the outlet, to increase flow rate capacity.

The length of the second portion is minimized by positioning the bend172 of the second portion 112 directly adjacent the flange 152, therebyminimizing or reducing flow distance.

Accordingly, it is to be understood that the embodiments of theinvention herein described are merely illustrative of the application ofthe principles of the invention. Reference herein to details of theillustrated embodiments is not intended to limit the scope of theclaims, which themselves recite those features regarded as essential tothe invention.

What is claimed is:
 1. A control valve comprising: a body having a flowpassage therethrough, the flow passage having an inlet, an outlet, afirst portion, and a second portion, the first portion having a firstaxis centered through the inlet, the second portion having a second axiscentered through the outlet, a flat first side, a flat second side, anda wall extending from the flat first side to the flat second side, thefirst axis parallel with the second axis, the opening of the valve seatextending through the flat second side, the flat second side beingexternal to the flow passage; a valve seat positioned at a junctionbetween the first portion and the second portion, the first portionbeing to an upstream side of the valve seat and the second portion beingto a downstream side of the valve seat, the valve seat having an openingtherethrough; a stem with a third axis oriented to intersect with theopening of the valve seat; and a seal attached to the stem, the stemconfigured to move axially to move the seal between a closed position,where the seal fills the opening through the valve seat, and an openposition, where the seal is distal from the valve seat.
 2. The controlvalve of claim 1, wherein the second portion includes a bend and afourth axis, the fourth axis angled obliquely relative to the secondaxis.
 3. The control valve of claim 2, wherein the fourth axis is angledbetween 25 and 45 degrees relative to the second axis.
 4. The controlvalve of claim 2, wherein the fourth axis is angled between 30 and 40degrees relative to the second axis.
 5. The control valve of claim 2,wherein the third axis is perpendicular to the fourth axis.
 6. Thecontrol valve of claim 1, wherein the first portion includes a bend anda fourth axis, the fourth axis centered through the junction, the fourthaxis angled obliquely relative to the first axis.
 7. The control valveof claim 6, wherein the fourth axis is angled between 45 and 65 degreesrelative to the first axis.
 8. The control valve of claim 6, wherein thefourth axis is angled between 50 and 60 degrees relative to the firstaxis.
 9. The control valve of claim 6, wherein the third axis is alignedwith the fourth axis.
 10. The control valve of claim 1, wherein a planeof the valve seat is angled between 25 and 45 degrees from parallel withthe first axis.
 11. The control valve of claim 1, wherein a plane of thevalve seat is angled between 30 and 40 degrees from parallel with thefirst axis.
 12. The control valve of claim 1, wherein the first portionincludes a first bend adjacent the junction, and the second portionincludes a second bend adjacent the junction, such that the firstportion intersects the second portion at approximately 90 degrees. 13.The control valve of claim 2, wherein a volume of the second portionbetween the body and the third axis expands from an end of the secondportion opposite the outlet around the third axis toward the outlet,beyond a plane containing the third axis and being perpendicular to thefourth axis, and then decreases to the outlet.
 14. The control valve ofclaim 1, wherein the first axis is colinear with the second axis.
 15. Acontrol valve body comprising: a flow passage having an inlet, anoutlet, a first portion, a second portion, and a junction of the firstportion with the second portion, the first portion being to an upstreamside of the junction, the first portion having a first axis, a firstbend, and a second axis, the second portion being to a downstream sideof the junction, the second portion having a third axis, a second bend,a fourth axis, a flat first side, a flat second side, and a wallextending essentially straight from the first side to the second side;and an opening to the second portion, the opening having a fifth axis,the first axis being centered through the inlet, the second axiscentered through the junction, the third axis centered through theoutlet, the fourth axis perpendicular to the second axis, and the fifthaxis aligned with the second axis.
 16. The control valve body of claim15, wherein the first axis is parallel with the third axis.
 17. Thecontrol valve body of claim 15, wherein the second axis is angledobliquely relative to the first axis, and the fourth axis angledobliquely relative to the third axis.
 18. The control valve body ofclaim 15, wherein the fourth axis is angled between 25 and 45 degreesrelative to the third axis.
 19. The control valve body of claim 15,wherein the fourth axis is angled between 30 and 40 degrees relative tothe third axis.
 20. The control valve body of claim 15, wherein thesecond axis is angled between 45 and 65 degrees relative to the firstaxis.
 21. The control valve body of claim 15, wherein the second axis isangled between 50 and 60 degrees relative to the first axis.
 22. Thecontrol valve body of claim 15, wherein the first portion intersects thesecond portion at approximately 90 degrees.
 23. The control valve bodyof claim 15, wherein a volume of the second portion between the body andthe second axis expands from the end of the second portion opposite theoutlet around the second axis toward the outlet, beyond a planecontaining the second axis and being perpendicular to the fourth axis,and then decreases to the outlet.